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Vehicle SimulationProOpt presentation

2009-10-15Martin Öman

Agenda:

1. History CAE at Saab Automobile AB

2. From Hardware-Based to Virtual Vehicle Development

3. Virtual Vehicle Development Process

4. CAE Organisation and CAE tools

5. Summary

6. Q& A

– Stiffness

– Strength

– Durability

– Crashworthiness

– Noise & Vibrations

– Aerodynamics

– Vehicle Dynamics

Vehicle Simulation, CAE disciplines

Saab 99

1976, 3800

Elements

1995, 22000

Elements

Saab 93

Saab

9000

1983, 5000

Elements

Saab 95

1999, 207000 Elements

History, CAE at Saab Automobile AB

Model size over time

Saab 93 Sport Sedan

2002, 470000 Elements

2003, 1 300 000 Elements

2008, 2 000 000 Elements

History, CAE at Saab Automobile AB

Model size over time

FutureFutureFuture

•Synthesis-Driven

•Hardware Supported

•Hardware-Driven

•Analysis Supported

Virtual Vehicle

Development

Hardware-Based

Vehicle

Development

StrategyStrategyStrategy

PastPastPast

MathMath--Based

Based

Synthesis Driven

Synthesis Driven

From Hardware-Based Vehicle Development

to Virtual Vehicle Development

CAE Method Development Process – R-L-MS

tra

teg

ies

Vehicle Tests

Simulation

Rig/Bench Tests

Road Lab Math

Years

Mule Alpha Beta 1 Gamma Pilot Beta 2

VEHICLE HARDWARE

PHASES

Engineering

Start Serial Tool

Release

Start of

production

Styl. / Pack.

Freeze

Past:

Now:

From Hardware-Based Vehicle Development

to Virtual Vehicle Development

VPI CSO100%VDR SORP PR

-144 -86-108 0

DSI

-172

Virtual Assessments

IV BuildIV Build PVVPVVMulesMulesPhysical BuildsPhysical Builds

ViniVA

-173VAVA

-145VDSOVA

-125VCVA

-110VSVA

-99VIVA

-87VPVA

-52

CVER

-109

SVER P/IVBR

-98

IVER(LL)

-86

FPVC

-29

DSO

-120

= Math Data Sync Points

Advantages using CAE

Using CAE in an efficient way can result in:

Competitive advantage

• significant time reductions

• product cost savings

• quality improvement (achieve consistent performance)

• increased product design innovation

Agenda:

1. History CAE at Saab Automobile AB

2. From Hardware-Based to Virtual Vehicle Development

3. Virtual Vehicle Development Process

4. CAE Organisation and CAE tools

5. Summary

6. Q& A

Vehicle Systems

– Body

– Interior

– Chassis

– Electrical Systems

– HVAC & Powertrain Cooling

Vehicle Integration

– Aerodynamics

– Energy

– Human Vehicle Integration– Noise & Vibration

– Safety

– Vehicle Dynamics

Vehicle Architecture

– Physical Integration

Vehicle Systems

– Body

– Interior

– Chassis

– Electrical Systems

– HVAC & Powertrain Cooling

Vehicle Integration

– Aerodynamics

– Energy

– Human Vehicle Integration– Noise & Vibration

– Safety

– Vehicle Dynamics

Vehicle Architecture

– Physical Integration

CAE

CAE – the engine in the daily development work

Virtual Vehicle Stages – milestones in the VDP

SORP 100%VDR

VPV

Morphed

Level 2 Math

Level 1 Math

DSI

VAV

Released

Released

Released

VCV VSV VIV

SVER IVBR

LL IVER

CVER

DSO

VIniV

Final Surface

Level 3 Math (Closures a Level

2)

Level 3 Math

Initial Surface

Level 1 Math

Level 0 Math

Level 2 Math

VDSOV

VPI

Virtual vehicle

stages

Global VVD Process Virtual Vehicle

Assessments Global Math Plan Standard Work Data Maturity

VxVA

Assessment periodModel build period

VxVA syncMath data delivery

w 00

Assessments acc to

loadcase lists for each area, ex:

w 07

Simulation

Supervisor/

Team Leader

Simulation Area

(VIA/VPPS Area)

Requiremen

t

VTS/SSTS/C

TS §

Requirement / Loadcase Simulation

method

VIVA

650

3Oct

07

VPVA

650

2Jul

08T. Sjödin Frontal Impact 3.2.1.2.2.1 30 mph Front (50th Male BELTED) F.SB.1.5 - -

T. Sjödin Frontal Impact 3.2.1.2.2.1 25 mph Front (50th Male UNBELTED) F.SB.1.20 -

T. Sjödin Frontal Occupant 3.2.1.2.2.1 25 mph Front (50th Male UNBELTED) F.SB.1.20 x X

T. Sjödin Frontal Impact 3.2.1.2.2.1 25 mph 30 DEG LEFT (50th Male UNBELTED) F.SB.1.22 -

T. Sjödin Frontal Occupant 3.2.1.2.2.1 25 mph 30 DEG LEFT (50th Male UNBELTED) F.SB.1.22 x X

T. Sjödin Frontal Impact 3.2.1.2.2.1 25 mph 30 DEG RIGHT (50th Male UNBELTED) F.SB.1.23 -

T. Sjödin Frontal Occupant 3.2.1.2.2.1 25 mph 30 DEG RIGHT (50th Male UNBELTED) F.SB.1.23 x X

T. Sjödin Frontal Impact 3.2.1.2.2.1 20 mph Front (50th Male UNBELTED) F.LS.1.7 - -

T. Sjödin Frontal Impact 3.2.1.2.2.1 20 mph 30 DEG LEFT (50th Male UNBELTED) F.LS.1.8 - -

T. Sjödin Frontal Impact 3.2.1.2.2.1 20 mph 30 DEG RIGHT (50th Male UNBELTED) F.LS.1.10 - -

T. Sjödin Frontal Impact 3.2.1.2.2.1 30 mph Front (5th Female BELTED) F.SB.1.11 - -

T. Sjödin Frontal Impact 3.2.1.2.2.1 25 mph Front (5th Female UNBELTED) F.SB.1.21 -

T. Sjödin Frontal Occupant 3.2.1.2.2.1 25 mph Front (5th Female UNBELTED) F.SB.1.21 x X

Summary sheet

VxVA presentation:

Virtual Vehicle Assessment Process

Agenda:

1. History CAE at Saab Automobile AB

2. From Hardware-Based to Virtual Vehicle Development

3. Virtual Vehicle Development Process

4. CAE Organisation and CAE tools

5. Summary

6. Q& A

0

Vehicle Simulation

Martin Öman

NVH Body Safety Interior

Eva-Lotta Saloniemi Tomas Sjödin Graeme McInally

Henrik Olsson Per Bryntheson Niclas Dagson Cecilia Åkerstedt

Kristoffer Thorn Johan Dahlberg Anders Gavelin*** Anders Eriksson

Stefan Froman Ingrid Jenshagen*** Robert Kylander***

Louse Lindell Peter Karlsson Claes Ljungqvist

Ann-Britt Ryberg Jessica Svensson

Tommy Spitza Jens Weber**

Johan Broberg*** Per Wilhelmsson

Ismail Benhayoun***

0 0

Chassis/VD Aero & Thermal SIM SIM

Fredrik Wrang* Håkan Danielsson* Annika Aleryd Krister Önnermalm

Gunnar Aglund Anders Johansson

Lennart Ekvall Kicki Klevmar ***

Johan Hultqvist Jesper Marklund**** * HC not belonging to SimulationGabriel Palmnäs*** Emil Svedung ** On parental leave

*** Temp Hire**** Ph.D. Student

1

9

Carolina Kalliokorpi

Erik Engdahl**

0 4 0

00 3 0

4

37

1

806

Organisation:

Hybrid organization – combining the benefits and avoiding the

extremes of strict centralized and decentralized CAE org.

CAE groups reports to two organizations:

Direct Organization - Vehicle Simulation

Indirect Organization - Product Functional Organization (a Vehicle Systems or

Vehicle Integration area) handles the daily product related work in its domain.

Safety

CAE

Central CAE

Chassis

CAE

dyna

mics

Aero

dyna

mics

Vehicle

Dynamics

CAE

Aero

dyna

mics

Aerodynamics

CAE

Aero

dyna

mics

Body

CAE

Aero

dyna

mics

Interior

CAE

CAE

Noise &

Vibration

Direct org. Indirect org.

Staffing, Vehicle Simulation

In total 38 Engineers:

Project management: 3 Engineers (M. Sc.)

Stiffness/Strength/Durability: 12 Engineers (1 Ph.D, 10 M.Sc., 1B.Sc.)

Crashworthiness: 13 Engineers (1 Ph.D, 10 M.Sc., 2 B.Sc.)

Noise & Vibrations: 3 Engineers (1 Ph.D, 2 M.Sc.)

Aerodynamics: 4 Engineers ( 4 M.Sc.)

Vehicle Dynamics: 2 Engineer (2 M.Sc.)

Years of working experience within CAE:

30% of the Staff have more than 10 Years

50 % of the Staff have between 5 and 10 Years

20% of the Staff have less than 5 Years

CAE Softwares

HyperWorks

HyperMesh

Hyperview

Hyperstudy

Optistruct

Motionview

LS-Dyna

Nastran

Adams

Abaqus

Fluent

LMS Virtual Lab

Matlab

Summary

Computer Aided Engineering (CAE) is a seamless integrated

process at Saab Automobile AB. Simulations is the “engine” in

our daily work to generate engineering solutions. Our intensive

use of CAE results in:

• significant time reductions

• product cost savings

• quality improvements

• an increased product

design innovation

Mule Alpha Beta 1 Gamma Pilot Beta 2

VEHICLE HARDWARE

PHASES

Engineering

Start Serial Tool

Release

Start of

production

Styl. / Pack.

Freeze

VPI CSO100%VDR SORP PR

-144 -86-108 0

DSI

-172

Virtual Assessments

IV BuildIV Build PVVPVVMulesMulesPhysical BuildsPhysical Builds

ViniVA

-173VAVA

-145VDSOVA

-125VCVA

-110VSVA

-99VIVA

-87VPVA

-52

CVER

-109

SVER P/IVBR

-98

IVER(LL)

-86

FPVC

-29

DSO

-120

= Math Data Sync Points

Past:

Now: